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Air-Cooled Gas Coolers

Air-cooled gas coolers to remove excess heat from a gas stream

Excess heat from a gas stream is lost to the atmosphere while the gas product is cooled close to ambient temperatures. Air-cooled gas coolers are used to remove this excess heat. Air-cooled gas coolers are used for a range of applications. These include CO2 cooling in refrigeration systems, also inter-cooling and after-cooling of compressor gas streams.

What you can expect from us

High-pressure capability

Our designs meet the highest pressure requirements, whether it is for a gas compression cycle or other gas cooling applications. In all cases, we consider PED requirements section by section.

Optimum header designs 

We use tubular or box header arrangements, depending on the pressure and dimensional configuration of the cooler.

Bespoke configurations

Where the cooler is to be integrated with your equipment, we will closely work with you on the designs to obtain the most beneficial arrangement.


How air-cooled gas coolers work

An air-cooled gas cooler is utilised to remove excess heat from a process gas stream. The gas stream may be at low, medium or high-pressure, depending on the application. At low pressure, the gas side heat transfer coefficient is, generally, low as the gas density is also low. Tube inserts can enhance the heat transfer coefficient if specifications permit.

As pressures increase, the increased density of the gas leads to increased coefficients. The optimum design requires less tube-side coefficient enhancement.

As the highest pressures, the mechanical design of the cooler becomes a more significant issue. In these cases, Sterling designs the high-pressure cooling sections for pressures over 5,600 bar. At these pressures, the heat exchanger is a fully welded construction with thick wall tubes.

For compressor systems, the excess heat generated during the compression cycle must be dissipated. The cooler is split into several stages, each operating at differing tube-side pressures. The stages of the cooler are mounted in series; each has a different mechanical design pressure, but all have similar cross-sections for the cooling air path.


As a recognised manufacturer of air-cooled gas coolers, we can help you to get the best equipment for your application. However, if you feel you need another type of heat exchanger, visit our products and services page or contact us.

Customised heat exchangers

Over 100 years of design & manufacturing knowledge

Your partner for the entire lifecycle of your business

We have purchased gas coolers for our air compression systems. Sterling Thermal Technology has created a combination of heat exchange sections to allow us to configure multistage cooling and integrate it with our compression cycle. Each customer-specific requirement can be optimised, using the range of inter-stage coolers designed by Sterling TT.

Talk to us..

We customise our heat exchange solution to meet your requirements, so contact us today to discover the right equipment for you.

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